Concrete structure



. D. MORLEY CONCRETE STRUCTURE July 15, 1924.

. 1920 2 Sheets-Sheet. l

Filed April 5 July l5 1924.

C. D. MORLEY CONCRETE STRUCTURE Filed April 5, 1920 2 Sheets-Sheet 2 Patent/ed `lilly 15,' 1924.

' CHARLES D. MORLEY, OF ST. `LOUIS, MISSOURI.

CONCRETE STRUCTURE. j

Application jled April 5,

provement in Concrete Structures, o f which the following is a specification. A

My invention relates to reinforced structures s uch as dwelling houses and to processes of building them. It has for its principal objects to dispense with the use of much of the 4elaborate and expensive temporary form work heretofore commonly used in building concrete structures, to adapt structural members to serve as forms during the building of-the structure and as component parts of the finished structure, and te simplify and cheapen the process of building such structures. My invention consists principally in using for forms for the concrete to be cast in situ reinforced concrete members suitable for such use and adapted to constitute permanent structural elements of the finished structure. My invention further consists inthe process andy in the parts and combinations of parts hereinafter described and claimed. In the drawings, which form `part of this specification and wherein like reference characters indicate like parts wherever they occur,

Fig. 1 is a perspective view showing in an early stage of construction a building made according to my invention.

Fig. 2 is a perspective View showing a portion of a concrete footing with a precast wall unit an-d precast column units arranged thereon.

Fig. 3 is a perspective view of a'precast floor slab.

Figs. 4, 5 and 6 are perspective views ofl the precast column members. f

Fig. 7 is a yperspective view of a precast column.

Fig. 8 is a horizontal sectional view show# ing a ltypical wall and column construction.

Fig; 9 is a. perspective view of a typical girder form, and

Fig. 1() is a perspective view of an inside beam form.

The structure illustrated in the drawings is a dwelling house which comprises footings, walls and columns on the footings, beams or girders and floors, all made of concrete. The footings, beams, some of the columns and part of the walls are. all cast in situ; but the forms in which the beams and 1920. Serial No. 371,201.

columns are molded in situ are precast and adapted to become permanent and effective parts of said beams and walls respectively. The lfloors are also made of precast slabs adapted to be integrated with the beams that support them.

The basement walls of the structure comprise precast 'slabs 1 of reinforced concrete, portions of the reinforcing bars 2 of said slabs projecting from the ends thereof. Said slabs are disposed vertically on edge and parallel with each other to form hollow walls; the space'between them may be filled to about the level of the ground with reinforced concrete 3. The walls rest on concrete footings 4. The reinforcing bars 2 of the precast wall slabs and the reinforcing bars 5 of the concrete filling project into the footings 4. The precast wall slabs 1 preferably have smooth outside surfaces. The inner surfaces have raised marginal portions 6 to furnish a good bond between said Iprecast slabs 1 andv the concrete filling 3 and also to provide `relatively large joints between said precast slabs. The edges of said slabs have grooves. therein adapted to receive cement 7 to form a key for abutting slabs. The outside concrete columns comprise precast members arranged to constitute a hollow column form and a filling 8 of concrete in said form whereby said form members and-said concrete cast in situ together constitute a column which has substantially the character of a monolithic construction. Preferably, said precastcolumn slabs are of the kind illustrated in Figs. 2 and 5, comprising an angular slab 9 adapted to constitute two sides of the colunm and slabs 10 adaptedto cooperate therewith to constitute a column form. Said precast column slabs have raised portions 11von the sides facing inwardly of the column so that they will be firmly bonded to the reinforced concrete filling 8. Girders or beams comprising reinforced` concrete forms 12 filled with reinforced concrete 13 are supported by said columns and rest on the upper edges of the pre-A elast wall slabs 1. Said girder forms 12 are of channel shape and preferably have one side wall shorter than the other. The bottoms of said girder=- forms have holes 14 therein at intervals to permit the reinforcing` comprise precast channel shaped reinforced concrete members and reinforced concrete 16 therein. The

. iioor comprises precast reinforced concrete 'forcing bars 18 of said floor slabs project into the beams 13 and girders 16l respectively. 'The intermediate beams may be supported on -precast columns 19..

Precast wall slabs 2O like those above described constitute the walls of the upper stories of the building. These slabs are disposed vertically on edge and parallel to each other along the margins of the girders 21, thus forming hollow curtain walls extending from' column to column. The ends of the reinforcing bars 22 of said precast wall slabs extend into the girders 21 as above described in the case of the basement walls and footings. rlhe beams 23 and floor slabs 24 are the same as those above described.

Partitions between rooms are formed by precast slabs or units similar to those used in the outside walls. Said units are provided with. suitable nailing blocks, furring strips and the like cast therein. Doors, windows and other openings are preferably made as wide as a wall unit or a multiple thereof. Units adjoining said doors and windows have suitable provision for securinthem.

he upper beams 26 are adapted to support a roof of any desired type. The building may have a flat roof, in which case a wall of precast hollow units may be formed along the upper .outside beams at the front and sides of the building.

If the building is to have a pitch roof,

i bolts or dowel pins 27V are embedded in the upper outside beams. Wooden plates 28 are secured to the beams by means of said bolts and the roof supporting members are suitably secured to said wooden plates.

The process of erecting buildings according-to my invention is as follows: The concrete footings for the walls and columns are poured first and their upper surfacescarefully smoothed and levelled, and. while the concrete is still soft, slots or holes are formed therein of suitable size and in proper position to receive reinforcing bars' projecting from the lower edges of the precast' wall slabs or units. Before the concrete footings harden, the lower ends of le Vertical reinforcing bars for the walls and columns are worked into position in the footings by which they are firmlyheld in vertical positionwhen the concrete hardens. The slots in said footings are then filled with suitable cement or concrete and the inside `row of l precast wall units isfarranged in position edgewise along the margins of the footings,

work comprising vertical struts 31 and horizontally arranged braces and beam supports 32. After the innerv wall units have been positioned, the precast units 'for the inner sides of the corner columns are arranged in position. The outer wall units and coli umn members are arranged in similar manner and suitably braced-so as to be held 1n pos1t1on while the concrete cast therem is hardening. The `window sills and door" frames are arranged in position as desired, the spaces between the frames and the coricrete units preferably being filled with a plastic oil cement so as to make weather proof joints. Concrete is then poured .into the spacebetween the precast slabs, the concrete level. y

rlhe precast girder forms are then placed in position resting on the columns'and on the upper edges of the precast Wall units. A suitable layer of mortar or cement is arranged between the tops of the wall/ units and the bottoms of the beam forms. Precast reinforced concrete `members constituting forms for intermediate beams are then arranged on the temporary wooden false work or on precast concrete columns and the precast floor slabs are laced in position as above described. `fter the floor slabs have been laid, beam reinforcement is placed in the beam forms, and the beam and column lforms are filled with concrete. The process of building additional stories is similar to that above described and .the partitions between rooms, doors, windows and transoms and the like may be arranged as desired. K

The oors and walls may be finished as desired. The floor slabs and the precast wall units can be made under factory conditions and can thus have a uniform finish preferably extending above the ground. I

and appearanceand a quality much Superior to that of concrete members cast in sltu under ordinary working conditions. It 1s further noted that the precastroncrete I forms constitute component parts of the finished structure, thus cheapening the costy and lessening, the diiiiculty of erecting buildings and that the process of'construction lis such that the precast members can be easily positioned byordinary workmen without danger of being misplaced thus in- The precast' members can be economically. made and can be given special treatment to obtain any desired finish. It is possible to give these units their yfinal finish in the factory so that whenthe buildin is erected, v

no -additional treatment isl nee ed for the walls or floors. My process is applicable to. concrete structures generally and not merely to dwellings of the kind described.

The units for the basement wallsmay be made heavy enough to withstand the earth `pressure and, these walls may be hollow like the upper walls. In many buildings it is unnecessary to use the poured columns above described and the load is borne by the precast wall members. It will be understood that any desired kind of reinforcement may be used and that other modifications may be made without departing from my invention.

What I claim is: 1. A reinforced concrete structure comprising vertically disposed precast' slabs of reinforced concrete constituting hollow walls and column forms, a filling of reinforced concrete in said column forms and integratved therewith, precast reinforced concrete floor slabs, precast concrete beam forms filled with reinforced concrete to constitute beams, reinforcementprojecting from said walls, column forms yand floor slabs into said beams, said columns and beams consti-y tuting` the load carrying members of said structure. v

2. In a concrete structure, a hollow wall comprising a reinforced concrete footing and precast reinforced concrete wall'. members` 

